SCADA Basics

Before discussing about the architecture of SCADA and different types of SCADA systems,
primarily we must know a few SCADA basics. Consider the block diagram of SCADA
system shown in the figure which consists of different blocks, namely Human-machine
Interface (HMI), Supervisory system, Remote terminal units, PLCs, Communication
infrastructure and SCADA Programming.

Basics of SCADA

1. Human-machine Interface (HMI)

It is an input-output device that presents the process data to be controlled by a human

operator. It is used by linking to the SCADA system’s software programs and databases for
providing the management information, including the scheduled maintenance procedures,
detailed schematics, logistic information, trending and diagnostic data for a specific sensor or
machine. HMI systems facilitate the operating personnel to see the information graphically.

Mr.S.Prince Samuel ,AP/EIE 16EI324 PLC & SCADA

 Human-Machine Interface

2. Supervisory System

Supervisory system is used as server for communicating between the equipment of the
SCADA system such as RTUs, PLCs and sensors, etc., and the HMI software used in the
control room workstations. Master station or supervisory station comprises a single PC
in smaller SCADA systems and, in case of larger SCADA systems, supervisory system
comprises distributed software applications, disaster recovery sites and multiple
servers. These multiple servers are configured in a hot-standby formation or dual-
redundant, which continuously controls and monitors in case of a server failure for
increasing the integrity of the system.

3. Remote Terminal Units

Physical objects in the SCADA systems are interfaced with the microprocessor
controlled electronic devices called as Remote Terminal Units (RTUs). These units are
used to transmit telemetry data to the supervisory system and receive the messages
from the master system for controlling the connected objects. Hence, these are also
called as Remote Telemetry Units.

4. Programmable Logic Controllers

In SCADA systems, PLCs are connected to the sensors for collecting the sensor output
signals in order to convert the sensor signals into digital data. PLCs are used instead of
RTUs because of the advantages of PLCs like flexibility, configuration, versatile and
affordability compared to RTUs.

Programmable Logic Controllers

5. Communication Infrastructure

Generally the combination of radio and direct wired connections is used for SCADA
systems, but in case of large systems like power stations and railways SONET/SDH are

Mr.S.Prince Samuel ,AP/EIE 16EI324 PLC & SCADA

frequently used. Among the very compact SCADA protocols used in SCADA systems –
a few communication protocols, which are standardized and recognized by SCADA
vendors – send information only when the supervisory station polls the RTUs.

6. SCADA Programming

SCADA programming in a master or HMI is used for creating maps and diagrams
which will give an important situational information in case of an event failure or
process failure. Standard interfaces are used for programming most commercial
SCADA systems. SCADA programming can be done using derived programming
language or C language.

Architecture of SCADA

Generally the SCADA system includes the following components: local processors,
operating equipment, PLCs, instruments, remote terminal unit, intelligent electronic
device, master terminal unit or host computers and a PC with human machine
interface.

Architecture of SCADA

The block diagram of SCADA system shown in the figure represents the basic SCADA
architecture. The SCADA (supervisory control and data acquisition) systems are different
from distributed control systems that are commonly found in plant sites. When distributed
control systems cover the plant site, SCADA system cover much larger geographic areas.

Above figure depicts an integrated SCADA architecture which supports TCP/IP, UDP and
other IP based communication protocols as well as industrial protocols like Modbus TCP,
Modbus over TCP or Modbus over UDP. These all work over cellular, private radio or
satellite networks.

Mr.S.Prince Samuel ,AP/EIE 16EI324 PLC & SCADA

In complex SCADA architectures, there are a variety of wired and wireless media &
protocols involved in getting data back to the monitoring site. This allows implementation of
powerful IP based SCADA networks over landline, mixed cellular and satellite systems.
SCADA communications can utilize a diverse range of wired and wireless media.

The choice of the existing communication depends on the characterization of a number of

factors. The factors are remoteness, available communications at the remote sites, existing
communications infrastructure, polling frequency and data rates. These factors impact the
final decision for SCADA architecture. Therefore, a review of SCADA systems evolution
allows us to better understand many security concerns.

4 Types of SCADA systems

There are different types of SCADA systems that can be considered as SCADA architectures
of four different generations:

1. First Generation: Monolithic or Early SCADA systems,

2. Second Generation: Distributed SCADA systems,
3. Third Generation: Networked SCADA systems and
4. Fourth Generation: Internet of things technology, SCADA systems

1. Monolithic or Early SCADA Systems

Minicomputers are used earlier for computing the SCADA systems. In earlier times, during
the time of first generation, monolithic SCADA systems were developed wherein the
common network services were not available. Hence, these are independent systems without
having any connectivity to other systems.

Monolithic or Early SCADA Systems

All the remote terminal unit sites would connect to a back-up mainframe system for
achieving the first generation SCADA system redundancy, which was used in case of failure
of the primary mainframe system. The functions of the monolithic SCADA systems in the
early first generation were limited to monitoring sensors in the system and flagging any
operations in case of surpassing programmed alarm levels.

2. Distributed SCADA Systems

Mr.S.Prince Samuel ,AP/EIE 16EI324 PLC & SCADA

In the second generation, the sharing of control functions is distributed across the multiple
systems connected to each other using Local Area Network (LAN). Hence, these were termed
as distributed SCADA systems. These individual stations were used to share real-time
information and command processing for performing control tasks to trip the alarm levels of
possible problems.

Distributed SCADA Systems

The cost and size of the station were reduced compared to the first generation system, as each
system of the second generation was responsible for performing a particular task with
reduced size and cost. But even in the second generation systems also the network protocols
were not standardized. The security of the SCADA installation was determined by a very few
people beyond the developers, as the protocols were proprietary. But generally the security of
the SCADA installation was ignored.

3. Networked SCADA Systems

The current SCADA systems are generally networked and communicate using Wide Area
Network (WAN) Systems over data lines or phone. These systems use Ethernet or Fiber
Optic Connections for transmitting data between the nodes frequently. These third generation
SCADA systems use Programmable Logic Controllers (PLC) for monitoring and adjusting
the routine flagging operators only in case of major decisions requirement.

Networked SCADA Systems

Mr.S.Prince Samuel ,AP/EIE 16EI324 PLC & SCADA

The first and second generation SCADA systems are limited to single site networks or single
building called as sealed systems. In these systems, we can not have any risk compared to the
third generation SCADA system which are connected to the internet causing the security
risks. There will be several parallel working distributed SCADA systems under a single
supervisor in network architecture.

4. Internet of Things

In fourth generation, the infrastructure cost of the SCADA systems is reduced by adopting
the internet of things technology with the commercially available cloud computing. The
maintenance and integration is also very easy for the fourth generation compared to the
earlier SCADA systems.

Internet of Things

These SCADA systems are able to report state in real time by using the horizontal scale from
the cloud computing facility; thus, more complex control algorithms can be implemented
which are practically sufficient to implement on traditional PLCs.

The security risks in case of decentralized SCADA implementations such as a heterogonous

mix of proprietary network protocols can be surpassed using the open network protocols such
as TLS inherent in the internet of things which will provide comprehendible and manageable
security boundary.

Applications of SCADA

SCADA systems are used for monitoring a variety of data like flows, currents, voltages,
pressures, temperatures, water levels, and etc., in various industries. If the system detects any
abnormal conditions from any monitoring data, then the alarms at the central or remote sites
will be triggered for alerting the operators through HMI.

Mr.S.Prince Samuel ,AP/EIE 16EI324 PLC & SCADA

There are numerous applications of SCADA systems, but a few most frequently used
SCADA applications include:

1. SCADA In Manufacturing Industries

In manufacturing industries the regular processes like running the production systems to meet
the productivity targets, checking the number of units produced and counting the completed
stages of operations along with temperatures at various stages of the manufacturing process,
and so on, are taken care by using the SCADA application.

2. SCADA Application in Waste Water Treatment and Distribution Plants

Wastewater treatment plants are of different types such as surface-water treatment and a well
water treatment system in which many control systems and automation processes are
involved in water treatment and distribution systems. SCADA systems are used for
controlling the automatic operations of the equipment used like backwashing the filters based
on the hours of working or amount of water flow through the filters.

Waste Water Treatment and Distribution Plants

In distribution plants the water tank levels, pressure of system, temperature of plant,
sedimentation, filtration, chemical treatment and other parameters or processes are controlled
using the SCADA applications such as PLCs, PC based workstations which are connected
each other using Local Area Network (LAN) such as Ethernet.

3. SCADA in Power System

Power system can be defined as constituent of power generation, transmission and

distribution. All these sectors are needed to be monitored regularly for improving the system
efficiency. Thus, the application of SCADA in power system improves the overall efficiency
of the system by providing the supervision and control over the generation, transmission and
distribution systems. SCADA in the power system network increases the system’s reliability
and stability for integrated grid operation.

Mr.S.Prince Samuel ,AP/EIE 16EI324 PLC & SCADA

 SCADA in Power System

Wireless SCADA

In large scale industries like power plants, steel plants and so on, many processes and
operations such as movement of conveyer belts for coal or product transport, boiler heat
temperature, etc. are to be monitored continuously and there is need to control the factors
affecting these parameters. So, application of wireless SCADA will provide better control
over the required control systems and operations.

Wireless SCADA Block Diagram

In this project 2.4 GHz wireless transmitter and USB receiver are used for sending and
receiving the data collected from the temperature sensors which interface with 8051
microcontroller. If the temperature goes beyond the set limit whether the low limit or high

Mr.S.Prince Samuel ,AP/EIE 16EI324 PLC & SCADA

limit, then the microcontroller sends commands to the relays to turn on or off based on the
command signal.

Monitoring and controlling of multiple operations in maximum number of industries are

being automatically controlled by most advanced SCADA technology implementations.
Already we are observing that many industrial operations are automatically controlled using
the application of SCADA system technology, but still many researchers are working to
develop more efficient SCADA systems for adopting full automatic control of all types of
industrial operations. Having any queries and ideas? Post your comments in the comment
section below for any technical help for implementing your ideas to develop real time
projects.

Mr.S.Prince Samuel ,AP/EIE 16EI324 PLC & SCADA